Polymer-modified asphalt compositions

ABSTRACT

A modified-asphalt composition prepared by introducing a diene end-capped block copolymer with a molten asphalt composition.

This application claims priority from U.S. Provisional PatentApplication Ser. No. 60/925,463, filed Apr. 20, 2007, which isincorporated herein by reference.

FIELD OF THE INVENTION

One or more embodiments of this invention relate to the use of dieneend-capped polymers in the production of modified-asphalt compositions.

BACKGROUND OF THE INVENTION

Asphalt paving compositions, which include a mixture of asphalt binderand aggregate, have long been employed in the manufacture of pavements.The asphalt binder compositions often included polymeric additives andare therefore often referred to as modified or polymer-modified asphaltbinder compositions. The presence of polymeric materials is believed toimprove the behavior of the pavements, particularly at extremetemperatures.

While elastomeric polymers having low crystallinity are oftenadvantageously employed, the presence of high Tg polymers also producesbenefit. Therefore, particularly useful polymers include blockcopolymers including low Tg amorphous segments or blocks and high Tgamorphous segments or blocks. For example, block copolymers including ablock of styrene and a block of butadiene may be used including polymerssuch as block styrene-butadiene-styrene (SBS).

In manufacturing the modified asphalt binder compositions, polymer isintroduced with molten asphalt. Under sufficient conditions of mixingand/or shear, the polymer is dissolved and/or dispersed into themolten-asphalt composition. It is desirable to uniformly disperse thepolymer throughout the composition.

It has been discovered that certain polymers, such asstyrene-butadiene-styrene block polymers do not disperse as efficientlyinto the molten asphalt. This is especially true with high molecularweight polymers. As a result, greater energy requirements and time arerequired to achieve a desirable dispersion of the polymer within theasphalt.

Conventional approaches to improving the dispersibility of the polymersinto the molten asphalt includes the use of lower molecular weightpolymers, which generally disperse more readily into the asphaltcomposition. Unfortunately, by using lower molecular weight polymers,the advantages sought by the use of a higher molecular weight polymerscannot be fully achieved. For example, certain binder and/or pavementperformance ratings cannot be achieved with low molecular weightpolymers.

Thus, there is a need to improve the dispersibility of polymers,particularly polymers including high Tg blocks, without deleteriouslysacrificing performance attributes that are advantageously achieved withhigher molecular weight polymers.

SUMMARY OF THE INVENTION

One or more embodiments of the present invention provides amodified-asphalt composition prepared by introducing a diene end-cappedblock copolymer with a molten asphalt composition, where the blockcopolymer is defined by the formula

α-(D-V-d)_(x)

where each D is independently a polydiene block, each V is independentlya vinyl aromatic block, each d is a polydiene end cap, α is a couplingmoiety, and x is an integer from 2 to 10.

One or more embodiments of the present invention also provides acopolymer for forming a modified asphalt composition, the copolymercomprising a block copolymer defined by the formula

α-(D-V-d)_(x)

where each D is independently a polydiene block, each V is independentlya vinyl aromatic block, each d is a polydiene end cap, α is a couplingmoiety, and x is an integer from 2 to 10.

One or more embodiments of the present invention also provides a methodfor forming a modified asphalt composition, the method comprisingintroducing a diene end-capped block copolymer with a molten asphaltcomposition, where the block copolymer is defined by the formula

α-(D-V-d)_(x)

where each D is independently a polydiene block, each V is independentlya vinyl aromatic block, each d is a polydiene end cap, α is a couplingmoiety, and x is an integer from 2 to 6.

One or more embodiments of the present invention also provides apavement prepared by depositing onto a surface an asphalt pavingcomposition prepared with a modified-asphalt composition prepared byintroducing a diene end-capped block copolymer with a molten asphaltcomposition, where the block copolymer is defined by the formula

α-(D-V-d)_(x)

where each D is independently a polydiene block, each V is independentlya vinyl aromatic block, each d is a polydiene end cap, α is a couplingmoiety, and x is an integer from 2 to 10.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In one or more embodiments, an asphalt-modified composition is preparedby introducing a diene end-capped block copolymer with a molten asphaltcomposition. The diene end-capped block copolymer may be simply referredto as the “end-capped copolymer.” It has been unexpectedly discoveredthat the diene end-capped block copolymers of one or more embodimentscan be advantageously mixed with molten asphalt. As a result, modifiedasphalt compositions can be efficiently prepared.

In one or more embodiments, the diene end-capped block copolymers can bedefined by the formula

α-(D-V-d)_(x)

where each D is independently a polydiene block, each V is independentlya vinyl aromatic block, each d is a polydiene end cap, α is a couplingmoiety, and x is an integer from 2 to 10.

In one or more embodiments, each d of the block copolymer, each of whichmay be independently defined, includes at least 10, in other embodimentsat least 40, in other embodiments at least 60, and in other embodimentsat least 80, in other embodiments at least 100, and in other embodimentsat least 120 mer units deriving from the polymerization of conjugateddiene monomer. In these or other embodiments, each d, which may beindependently defined, includes less than 500, in other embodiments lessthan 350, in other embodiments less than 250, in other embodiments lessthan 200, in other embodiments less than 180, in other embodiments lessthan 160, and in other embodiments less than 120 mer units deriving fromthe polymerization of conjugated diene monomer.

In one or more embodiments, each D of the block copolymer, each of whichmay be independently defined, includes at least 400, in otherembodiments at least 500, in other embodiments at least 650, and inother embodiments at least 700 mer units deriving from thepolymerization of conjugated diene monomer. In these or otherembodiments, each D, which may be independently defined, includes lessthan 1,200, in other embodiments less than 1,100, in other embodimentsless than 950, and in other embodiments less than 850 mer units derivingfrom the polymerization of conjugated diene monomer.

In one or more embodiments, each V of the block copolymer, each of whichmay be independently defined, includes at least 100, in otherembodiments at least 120, in other embodiments at least 145, in otherembodiments at least 160, in other embodiments at least 180, and inother embodiments at least 200 mer units deriving from thepolymerization of vinyl aromatic monomer. In these or other embodiments,each V, which may be independently defined, includes less than 500, inother embodiments less than 400, in other embodiments less than 300, inother embodiments less than 250, and in other embodiments less than 200mer units deriving from the polymerization of vinyl aromatic monomer.

In one or more embodiments, the ratio of the d mer units to the V merunits is at least 0.2:1, in other embodiments at least 0.3:1, in otherembodiments at least 0.4:1, in other embodiments at least 0.45:1, inother embodiments at least 0.52:1, and in other embodiments at least0.55:1. In these or other embodiments, the ratio of the d mer units tothe V mer units is less than 2.5:1, in other embodiments less than1.4:1, in other embodiments less than 1:1, in other embodiments lessthan 0.9:1, and in other embodiments less than 0.8:1. In one or moreembodiments, the ratio of the d mer units to the V mer units from about1:0.4 to about 1:5, and in other embodiments from about 1:0.7 to about1:3.

In one or more embodiments, the ratio of the V mer units to the sum ofthe D and d mer units may be at least 0.12:1, in other embodiments atleast 0.14:1, in other embodiments at least 0.16:1, and in otherembodiments at least 0.17:1. In these or other embodiments, the ratio ofthe V mer units to the sum of the D and d mer units may be less than1.2:1, in other embodiments less than 1.0:1, in other embodiments lessthan 0.5:1, in other embodiments 0.27:1, in other embodiments less than0.25:1, in other embodiments less than 0.22:1, and in other embodimentsless than 0.20:1. In one or more embodiments, the ratio of the V merunits to the sum of the D and the d mer units may be from about 0.15:1to about 0.23:1, and in other embodiments from about 0.17:1 to about0.19:1.

In one or more embodiments, the amount of V mer units present withrespect to the sum of the D and the d mer units may be represented asthe mole percent of bound V (e.g. bound styrene content). In one or moreembodiments, the mole percent of bound V is at least 12 mole %, in otherembodiments at least 14 mole %, in other embodiments at least 16 mole %,and in other embodiments at least 17 mole % based on the total moles ofmer units within the copolymer. In these or other embodiments, the molepercent of bound V is less than 70 mole %, in other embodiments lessthan 55 mole %, in other embodiments less than 40 mole %, in otherembodiments less than 37 mole %, in other embodiments less than 35 mole%, in other embodiments less than 30 mole %, and in other embodimentsless than 27 mole % based on the total moles of mer units within thecopolymer.

In one or more embodiments, the polydiene block defined by D and/or thepolydiene block defined by d is characterized by a vinyl content of atleast 15%, in other embodiments at least 18%, in other embodiments atleast 20%, and in other embodiments at least 22%. In these or otherembodiments, the polydiene block represented by d and/or D ischaracterized by a vinyl content of less than 40%, in other embodimentsless than 35%, in other embodiments less than 32%, and in otherembodiments less than 8%.

In one or more embodiments, x is 2. In other embodiments x is 4. Inother embodiments x is 6, and in other embodiments x is 9. In otherembodiments, x is an integer from at least 3, and in other embodimentsat least 4. In these or other embodiments, x is an integer from 2 toabout 20, or in other embodiments from about 2 to about 15.

In one or more embodiments, the mer units deriving from conjugated dienemonomer may derive from 1,3-butadiene, isoprene, 1,3-pentadiene,1,3-hexadiene, 2,3-dimethyl-1,3-butadiene, 2-ethyl-1,3-butadiene,2-methyl-1,3-pentadiene, 3-methyl-1,3-pentadiene,4-methyl-1,3-pentadiene, and 2,4-hexadiene. Mixtures of two or moreconjugated dienes may also be utilized. In one or more embodiments, themer units deriving from vinyl aromatic monomer may derive from monomersuch as styrene, and methyl styrene.

In those embodiments where x is 2, the diene end-capped block copolymeris a linear molecule. In these or other embodiments, this linear blockcopolymer may be characterized by a peak molecular weight (M_(p)) of atleast 40 kg/mole, in other embodiments at least 55 kg/mole, in otherembodiments at least 70 kg/mole, in other embodiments at least 90kg/mole, in other embodiments at least 100 kg/mole, and in otherembodiments at least 110 kg/mole as determined by GPC using polystyrenestandards. In these or other embodiments, particularly where the blockcopolymer is a linear molecule, the block copolymer may be characterizedby a peak molecular weight of less than 230 kg/mole, in otherembodiments less than 200 kg/mole, in other embodiments less than 170kg/mole, in other embodiments less than 150 kg/mole, and in otherembodiments less than 130 kg/mole. In these or other embodiments, thelinear molecule may be characterized by a molecular weight distributionof from about 0.8 to about 2, in other embodiments from about 0.9 toabout 1.6, and in other embodiments from about 1.1 to about 1.4.

Where x is 3, 4, and/or 6, the block copolymer is a star-branchedmolecule. In these or other embodiments, the star-branched blockcopolymer molecule may be characterized by a peak molecular weight of atleast 150, in other embodiments at least 200, in other embodiments atleast 225, and in other embodiments at least 250 kg/mole. In these orother embodiments, the star-branched block copolymer may becharacterized by a peak molecular weight of less than 700, in otherembodiments less than 500, in other embodiments less than 400, and inother embodiments less than 300 kg/mole. In these or other embodiments,the star-branched block copolymer may be characterized by a molecularweight distribution of from about 1.5 to about 4.0, and in otherembodiments from about 1.8 to about 2.7.

In one or more embodiments, the size of the diene end-capped blockcopolymer may be described with reference to the arm of the dieneend-capped block copolymer. For purposes of this specification, the armof the diene end-capped block copolymer is the D-V-d segment of thediene end-capped block copolymer. To the extent that the dieneend-capped block copolymer may be prepared via a coupling reactions(which will be described in greater detail herein below), the arm(D-V-d) may be equivalent (or substantially equivalent) to the basemolecular weight of the polymer (D-V-d) prior to coupling. In one ormore embodiments, the Mp (peak molecular weight) of the of the basepolymer or arm is at least about 45 kg/mole, in other embodiments atleast about 50 kg/mole, in other embodiments at least about 55 kg/mole,and in other embodiments at least about 60 kg/mole. In these or otherembodiments, the Mp (peak molecular weight) of the of the base polymeror arm is less than about 100 kg/mole, in other embodiments less thanabout 90 kg/mole, in other embodiments less than about 80 kg/mole, andin other embodiments less than about 75 kg/mole

In one or more embodiments, the diene end-capped block copolymer isintroduced with the molten asphalt within a mixture with a distinctpolymeric species (i.e. a polymer distinct from the diene end-cappedblock copolymer). Where the diene end-capped block copolymer is a linearmolecule (which may be referred to as a coupled block copolymer), themixture that is introduced with the molten asphalt may be characterizedby a melt index (ASTM D-1238, 2.16 kg @ 190° C.) of at least 1, in otherembodiments at least 3, in other embodiments at least 5, and in otherembodiments at least 7 dg/min. In these or other embodiments, themixture including the linear end-capped block copolymer may becharacterized by a melt index of less than 20, in other embodiments lessthan 15, in other embodiments less than 12, and in other embodimentsless than 10 dg/min.

In one or more embodiments, the distinct polymeric species that isincluded within the mixture with the linear diene end-capped blockcopolymer is a block copolymer defined by the formula d-V-D, where D, V,and d are defined above. In these or other embodiments, the mole ratioof the linear end-capped block copolymer and the distinct polymerdefined by the formula d-V-D is at least 1:0.8, in other embodiments atleast 1:1, and in other embodiments at least 1:1.5. In these or otherembodiments, the mole ratio of the linear end-capped block copolymer tothe distinct polymer d-V-D is less than 1:4, in other embodiments lessthan 1:3, and in other embodiments less than 1:2.5.

In one or more embodiments, where the diene end-capped block copolymeris a star-branched block copolymer, and the star-branched blockcopolymer is introduced to the molten asphalt within a mixture togetherwith a distinct polymer. In one or more embodiments, the mixture may becharacterized by a melt index of less than 2, in other embodiments lessthan 1, and in other embodiments less than 0.7 dg/min.

In one or more embodiments, the star-branched block copolymer isintroduced with the molten asphalt in a mixture together with a distinctpolymeric species defined by the formula d-V-D, where D, V, and d aredefined above. In these or other embodiments, the mole ratio of thediene end-capped branched block copolymer to the distinct d-V-D is atleast 0.5:1, in other embodiments at least 0.7:1, and in otherembodiments at least 0.9:1. In these or other embodiments, the moleratio of the diene end-capped branched block copolymer to the distinctd-V-D polymer is less than 9.5:1, in other embodiments less than 5:1, inother embodiments less than 2.5:1, in other embodiments less than 2:1,and in other embodiments less than 1.8:1.

In one or more embodiments, the block copolymers employed in the presentinvention can be synthesized by employing anionic polymerizationtechniques. In one or more embodiments, living polymers includeanionically polymerized polymers (i.e., polymers prepared by anionicpolymerization techniques). Anionically-polymerized living polymers maybe formed by reacting anionic initiators with certain unsaturatedmonomers to propagate a polymeric structure. Or, in other embodiments,other monomers such as epoxides or cyclic siloxanes, may be polymerizedby anionic polymerization. Throughout formation and propagation of thepolymer, the polymeric structure may be anionic and “living.” A newbatch of monomer subsequently added to the reaction can add to theliving ends of the existing chains and increase the degree ofpolymerization. A living polymer, therefore, includes a polymericsegment having a living or reactive end. Anionic polymerization isfurther described in George Odian, Principles of Polymerization, ch. 5(3^(rd) Ed. 1991), or Panek, 94 J. Am. Chem. Soc., 8768 (1972), whichare incorporated herein by reference.

Monomers that can be employed in preparing an anionically polymerizedliving polymer include any monomer capable of being polymerizedaccording to anionic polymerization techniques. These monomers includethose that lead to the formation of elastomeric homopolymers orcopolymers. Suitable monomers include, without limitation, conjugatedC₄-C₁₂ dienes, C₈-C₁₈ monovinyl aromatic monomers, and C₆-C₂₀ trienes.Examples of conjugated diene monomers include, without limitation,1,3-butadiene, isoprene, 1,3-pentadiene, 2,3-dimethyl-1,3-butadiene, and1,3-hexadiene. A non-limiting example of trienes includes myrcene.Aromatic vinyl monomers include, without limitation, styrene, α-methylstyrene, p-methylstyrene, and vinylnaphthalene. When preparingelastomeric copolymers, such as those containing conjugated dienemonomers and aromatic vinyl monomers, the conjugated diene monomers andaromatic vinyl monomers are normally used at a ratio of 95:5 to 50:50,and preferably 95:5 to 65:35.

Any anionic initiator can be employed to initiate the formation andpropagation of the living polymers. Exemplary anionic initiatorsinclude, but are not limited to, alkyl lithium initiators such asn-butyl lithium, arenyllithium initiators, arenylsodium initiators,aminoalkyllithiums, and alkyl tin lithiums. Other useful initiatorsinclude N-lithiohexamethyleneimide, N-lithiopyrrolidinide, andN-lithiododecamethyleneimide as well as organolithium compounds such asthe tri-alkyl lithium adducts of substituted aldimines and substitutedketimines, and N-lithio salts of substituted secondary amines. Stillothers include alkylthioacetals (e.g., dithianes). Exemplary initiatorsare also described in the following U.S. Pat. Nos. 5,332,810, 5,329,005,5,578,542, 5,393,721, 5,698,646, 5,491,230, 5,521,309, 5,496,940,5,574,109, 5,786,441, and International Publication Nos. WO 2004/020475and WO 2004/041870, which are incorporated herein by reference.

The amount of initiator employed in conducting anionic polymerizationscan vary widely based upon the desired polymer characteristics. In oneor more embodiments, from about 0.1 to about 100, and optionally fromabout 0.33 to about 10 mmol of lithium per 100 g of monomer is employed.

Anionic polymerizations are typically conducted in a polar solvent suchas tetrahydrofuran (THF) or a non-polar hydrocarbon such as the variouscyclic and acyclic hexanes, heptanes, octanes, pentanes, their alkylatedderivatives, and mixtures thereof, as well as benzene.

In order to promote randomization in copolymerization and to controlvinyl content, a polar coordinator may be added to the polymerizationingredients. Amounts range between 0 and 90 or more equivalents perequivalent of lithium. The amount depends on the amount of vinyldesired, the level of styrene employed and the temperature of thepolymerization, as well as the nature of the specific polar coordinator(modifier) employed. Suitable polymerization modifiers include, forexample, ethers or amines to provide the desired microstructure andrandomization of the comonomer units.

Compounds useful as polar coordinators include those having an oxygen ornitrogen heteroatom and a non-bonded pair of electrons. Examples includedialkyl ethers of mono and oligo alkylene glycols; “crown” ethers;tertiary amines such as tetramethylethylene diamine (TMEDA); linear THFoligomers; and the like. Specific examples of compounds useful as polarcoordinators include tetrahydrofuran (THF), linear and cyclic oligomericoxolanyl alkanes such as 2,2-bis(2′-tetrahydrofuryl) propane,di-piperidyl ethane, dipiperidyl methane, hexamethylphosphoramide,N—N′-dimethylpiperazine, diazabicyclooctane, dimethyl ether, diethylether, tributylamine and the like. The linear and cyclic oligomericoxolanyl alkane modifiers are described in U.S. Pat. No. 4,429,091,incorporated herein by reference.

Anionically polymerized living polymers can be prepared by either batchor continuous methods. A batch polymerization is begun by charging ablend of monomer(s) and normal alkane solvent to a suitable reactionvessel, followed by the addition of the polar coordinator (if employed)and an initiator compound. The reactants are heated to a temperature offrom about 20 to about 130° C. and the polymerization is allowed toproceed for from about 0.1 to about 24 hours. This reaction produces areactive polymer having a reactive or living end. Preferably, at leastabout 30% of the polymer molecules contain a living end. Morepreferably, at least about 50% of the polymer molecules contain a livingend. Even more preferably, at least about 80% contain a living end.

After formation of the functional polymer, a processing aid and otheroptional additives such as oil can be added to the polymer cement. Thefunctional polymer and other optional ingredients may then be isolatedfrom the solvent and optionally dried. Conventional procedures fordesolventization and drying may be employed. In one embodiment, thefunctional polymer may be isolated from the solvent by steamdesolventization or hot water coagulation of the solvent followed byfiltration. Residual solvent may be removed by using conventional dryingtechniques such as oven drying or direct drying. Alternatively, thecement may be directly dried.

As is known in the art of anionic polymerization, block copolymers canbe synthesized by sequentially polymerizing distinct monomer. Forexample, conjugated diene monomer can first be polymerized to form the dblock, and then vinyl aromatic monomer can be added to the solutioncontaining the live polymer to thereby form the V block, and thenadditional conjugated diene monomer can be added to the solutioncontaining the live polymer to form the D block. This living polymer,which can be represented by d-V-D^(⊖), where d, V, and D are definedabove, can then be coupled with a coupling agent. The residue of thiscoupling agent forms the a moiety.

Useful coupling agents include those compounds that can react with andserve to couple two or more living polymers together. In one or moreembodiments, useful coupling agents include monoesters. Usefulmonoesters include those defined by the formula

where R¹ is a mono-valent organic group and R³ is a mono-valent organicgroup.

In one or more embodiments, mono-valent organic groups may includehydrocarbyl groups such as, but not limited to, alkyl, cycloalkyl,substituted cycloalkyl, alkenyl, cycloalkenyl, substituted cycloalkenyl,aryl, substituted aryl, aralkyl, alkaryl, allyl, and alkynyl groups.These hydrocarbyl groups may contain heteroatoms such as, but notlimited to, nitrogen, oxygen, boron, silicon, sulfur, tin, andphosphorus atoms. In one or more embodiments, an ester group or a groupthat includes an ester linkage is included in one or more of themono-valent organic groups. As those skilled in the art appreciate,where the mono-valent organic group includes one or more ester linkages,the ester molecule may be a diester, triester, or other multi-ester.

In one or more embodiments, useful esters include those defined by thecompound

where R1 is a mono-valent organic group as defined above, and R3 is amono-valent organic group as defined above.

Particular examples of monoesters include butyl benzoate. Particularexamples of diesters include dioctyl terphthalate. Particular examplesof triesters include trioctyl trimellitate.

Useful coupling agents include monoesters such as butyl benzoate,diesters such as dioctyl terephthalate, or triesters such as trioctyltrimellitate. As is known in the art, the functionality of the couplingagent will dictate whether the block copolymer is a linear orstar-branched molecule.

In one or more embodiments, the coupling agent may include metal halidesor metalloid halides such as those that may be selected from the groupconsisting of compounds expressed by the formula (1) R¹ _(n)M¹X_(4-n),the general formula (2) M¹X₄, and the general formula (3) M²X₃, where R¹in the general formula (1) is the same or different and represents amono-valent organic group with carbon number of 1 to about 20, M¹ in thegeneral formulas (1) and (2) represents a tin atom, silicon atom, orgermanium atom, M² in the general formula (3) represents a phosphorousatom, X in the general formulas (1)-(3) represents a halogen atom, and nin the general formula (1) represents an integer of from 0 to about 3.

Exemplary compounds expressed by the general formula (1) may includehalogenated organic metal compounds, and the compounds expressed by thegeneral formulas (2) and (3) may include halogenated metal compounds.

In the case where M¹ represents a tin atom, the compounds expressed bythe general formula (1) can be, for example, triphenyltin chloride,tributyltin chloride, triisopropyltin chloride, trihexyltin chloride,trioctyltin chloride, diphenyltin dichloride, dibutyltin dichloride,dihexyltin dichloride, dioctyltin dichloride, phenyltin trichloride,butyltin trichloride, octyltin trichloride and the like. Furthermore,tin tetrachloride, tin tetrabromide and the like can be exemplified asthe compounds expressed by general formula (2).

In the case where M¹ represents a silicon atom, the compounds expressedby the general formula (1) can be, for example, triphenylchlorosilane,trihexylchlorosilane, trioctylchlorosilane, tributylchlorosilane,trimethylchlorosilane, diphenyldichlorosilane, dihexyldichlorosilane,dioctyldichlorosilane, dibutyldichlorosilane, dimethyldichlorosilane,methyltrichlorosilane, phenyltrichlorosilane, hexyltrichlorosilane,octyltrichlorosilane, butyltrichlorosilane, methyltrichlorosilane andthe like. Furthermore, silicon tetrachloride, silicon tetrabromide andthe like can be exemplified as the compounds expressed by the generalformula (2). In the case where M¹ represents a germanium atom, thecompounds expressed by the general formula (1) can be, for example,triphenylgermanium chloride, dibutylgermanium dichloride,diphenylgermanium dichloride, butylgermanium trichloride and the like.Furthermore, germanium tetrachloride, germanium tetrabromide and thelike can be exemplified as the compounds expressed by the generalformula (2). Phosphorous trichloride, phosphorous tribromide and thelike can be exemplified as the compounds expressed by the generalformula (3). In one or more embodiments, mixtures of metal halidesand/or metalloid halides can be used.

In one or more embodiments, a derives from the oligomerization ofdivinylbenzene with living polymer chains. According to theoreticalcalculations, this synthesis will yield a star polymer including 9branches or arms. As a result, the macromolecular structure of the blockcopolymer is a star branched polymer with 9 arms or branches.

In one or more embodiments, only portion of the d-V-D⊖ living polymersare coupled. After a partial coupling, the solution of living polymerand coupling polymer can be quenched, and isolation of the polymericspecies results in a polymer mixture including coupled polymer anduncoupled d-V-D polymer. This mixture can then be introduced with themolten asphalt to form the modified asphalt compositions employed in thepresent invention.

In one or more embodiments, particularly where the coupling of thed-V-D⊖ living polymers results in a linear di-coupled block copolymer,the living polymer solution may be coupled from about 10 to about 70%,in other embodiments from about 20 to about 40%, and in otherembodiments from about 25 to about 35%.

In one or more embodiments, particularly where the coupling of thed-V-D⊖ living polymers results in a star-branched block copolymer, theliving polymer solution may be coupled from about 50 to about 90%, inother embodiments from about 60 to about 80%, and in other embodimentsfrom about 65 to about 75%. In one or more embodiments, the livingpolymer solution may be coupled to at least 50%, in other embodiments atleast 60%, in other embodiments at least 70%, in other embodiments atleast 80%, in other embodiments at least 90%, and in other embodimentsat least 95%.

In one or more embodiments, the block copolymers of the presentinvention can advantageously be prepared in an organic solvent. Suitablesolvents include those organic compounds that will not undergopolymerization or incorporation into propagating polymer chains. In oneor more embodiments, these organic species are liquid at ambienttemperature and pressure. Exemplary organic solvents includehydrocarbons with a low or relatively low boiling point such as aromatichydrocarbons, aliphatic hydrocarbons, and cycloaliphatic hydrocarbons.Non-limiting examples of aromatic hydrocarbons include benzene, toluene,xylenes, ethylbenzene, diethylbenzene, and mesitylene. Non-limitingexamples of aliphatic hydrocarbons include n-pentane, n-hexane,n-heptane, n-octane, n-nonane, n-decane, isopentane, isohexanes,isopentanes, isooctanes, 2,2-dimethylbutane, petroleum ether, kerosene,and petroleum spirits. And, non-limiting examples of cycloaliphatichydrocarbons include cyclopentane, cyclohexane, methylcyclopentane, andmethylcyclohexane. Mixtures of the above hydrocarbons may also be used.As is known in the art, aliphatic and cycloaliphatic hydrocarbons may bedesirably employed for environmental reasons. The low-boilinghydrocarbon solvents are typically separated from the polymer uponcompletion of the polymerization.

One or more embodiments of the present invention provide a method forforming a modified asphalt binder composition that is useful forpreparing asphalt paving compositions. In one or more embodiments, themodified asphalt binder composition may be formed by introducing andmixing an asphalt binder, and a polymer. The modified asphalt bindercomposition may be combined with aggregate to form an asphalt pavingcomposition. In particular embodiments, the asphalt paving compositioncan be formed into pavements.

One or more embodiments, the asphalt binder compositions of the presentinvention are prepared by adding phosphorus pentasulfide to the asphaltcompositions in a manner consistent with co-pending U.S. Ser. No.11/644,557, which is incorporated herein by reference.

The term “asphalt binder” is used as understood by those skilled in theart and is consistent with the meaning provided by AASHTO M320. Whereasphalt binder has been combined with aggregate, the term “asphaltpaving composition” is employed. As used within this specification, theterms “asphalt” and “asphalt binder” may be used synonymously. Theasphalt binder material may be derived from any asphalt source, such asnatural asphalt, rock asphalt, produced from tar sands, or petroleumasphalt obtained in the process of refining petroleum. The asphaltbinder may be selected from those currently graded by AASHTO M320 andASTM D-6373, including Performance Graded Asphalt Binders. In otherembodiments, asphalt binders may include a blend of various asphalts notmeeting any specific grade definition. This includes air-blown asphalt,vacuum-distilled asphalt, steam-distilled asphalt, cutback asphalt orroofing asphalt. Alternatively, gilsonite, natural or synthetic, usedalone or mixed with petroleum asphalt, may be selected. Syntheticasphalt mixtures suitable for use in the present invention aredescribed, for example, in U.S. Pat. No. 4,437,896. In one or moreembodiments, asphalt includes petroleum derived asphalt and asphalticresidual. These compositions may include asphaltenes, resins, cyclics,and saturates. The percentage of these constituents in the overallasphalt binder composition may vary based on the source of the asphalt.

Asphaltenes include black amorphous solids containing, in addition tocarbon and hydrogen, some nitrogen, sulfur, and oxygen. Trace elementssuch as nickel and vanadium may also be present. Asphaltenes aregenerally considered as highly polar aromatic materials of a numberaverage molecular weight of about 2000 to about 5000 g/mol, and mayconstitute about 5 to about 25% of the weight of asphalt.

Resins (polar aromatics) include dark-colored, solid and semi-solid,very adhesive fractions of relatively high molecular weight present inthe maltenes. They may include the dispersing agents of peptizers forthe asphaltenes, and the proportion of resins to asphaltenes governs, toa degree, the sol- or gel-type character of asphalts. Resins separatedfrom bitumens may have a number average molecular weight of about 0.8 toabout 2 kg/mol but there is a wide molecular distribution. Thiscomponent may constitute about 15 to about 25% of the weight ofasphalts.

Cyclics (naphthene aromatics) include the compounds of lowest molecularweight in bitumens and represent the major portion of the dispersionmedium for the peptized asphaltenes. They may constitute about 45 toabout 60% by weight of the total asphalt binder, and may be dark viscousliquids. They may include compounds with aromatic and naphthenicaromatic nuclei with side chain constituents and may have molecularweights of 0.5 to about 9 kg/mol.

Saturates include predominantly the straight- and branched-chainaliphatic hydrocarbons present in bitumens, together with alkylnaphthenes and some alkyl aromatics. The average molecular weight rangemay be approximately similar to that of the cyclics, and the componentsmay include the waxy and non-waxy saturates. This fraction may fromabout 5 to about 20% of the weight of asphalts.

In these or other embodiments, asphalt binders may include bitumens thatoccur in nature or may be obtained in petroleum processing. Asphalts maycontain very high molecular weight hydrocarbons called asphaltenes,which may be soluble in carbon disulfide, pyridine, aromatichydrocarbons, chlorinated hydrocarbons, and THF. Asphalts or bituminousmaterials may be solids, semi-solids or liquids.

In one or more embodiments, the asphalt binders, prior to modification(i.e., prior to combination with unsaturated polymer or P₂S₅), may becharacterized by a PG rating of at least PG 64-22, in other embodimentsat least PG 52-28, and in other embodiments at least PG 52-34. It shouldbe noted that each of these exemplary asphalt binders have a temperatureperformance range of 86° C. While the selection of these asphalt bindersmay be advantageous desirable and certain embodiments, practice of thepresent invention advantageously allows for the use of a base asphaltbinder with a lower temperature range because this lower temperaturerange can be upgraded through practice of the present invention. Forexample, a PG 64-16, PG 58-22, or PG 52-28 can be modified to increaseits temperature range. As those skilled in the art appreciate, PG ratingrefers to Super Pave (Superior Performing Pavements) Performance Graded(PG) binder specifications as developed in the United States throughresearch funded by the Association of American Highway andTransportation Officials (AASHTO M320).

The modified asphalt binder compositions of this invention may alsoinclude those other ingredients or constituents that are commonlyemployed in the industry. For example, the compositions may includeanti-stripping compounds.

In other embodiments, curing agents can optionally be added to themodified asphalt binder compositions of this embodiment. Curing agentsmay include phenolic resins and elemental sulfur. One example is abismaleimide curing agent. Conventional amounts may be employed inpracticing this invention. In one or more embodiments, the need for acuring agent, particularly sulfur, is eliminated. In other words,asphalt binder compositions of the present invention can be preparedwithout the addition of a curing agent and/or a sulfur-containingcurative other than the phosphorus pentasulfide.

The asphalt binder compositions of the present invention may includefrom about 0.1 to about 10 parts by weight, in other embodiments fromabout 0.2 to about 6 parts by weight, and in other embodiments fromabout 0.5 to about 4 parts by weight polymer per 100 parts by weightasphalt binder. In these or other embodiments, the asphalt bindercompositions of the present invention may include less than 5 parts byweight, in other embodiments less than 4 parts by weight, in otherembodiments less than 3 parts by weight, in other embodiments less than2.5 parts by weight, in other embodiments less than 2 parts by weight,in other embodiments less than 1.8 parts by weight, in other embodimentsless than 1.5 parts by weight polymer per 100 parts by weight asphaltbinder. In these or other embodiments, the asphalt binder compositionsinclude at least 0.1 parts by weight, in other embodiments at least 0.5parts by weight, in other embodiments at least 0.7 parts by weight, inother embodiments at least 1.0 parts by weight, and in other embodimentsat least 1.2 parts by weight polymer per 100 parts by weight asphaltbinder.

In those embodiments where a curative is employed, the asphaltcompositions of this invention may include from about 0.1 to about 10,in other embodiments from about 0.2 to about 6, and in other embodimentsfrom about 0.5 to about 4 parts by weight curative per 100 parts byweight asphalt. In these or other embodiments, the formation of theasphalt binder compositions of the present invention may employ lessthan 3 parts, in other embodiments less than 1 parts, in otherembodiments less than 0.5 parts, in other embodiments less than 0.25parts, in other embodiments less than 0.1 parts, and in otherembodiments less than 0.01 parts by weight curative (e.g., free sulfuror elemental sulfur) per 100 parts by weight asphalt binder.

In one or more embodiments, the modified asphalt binder compositions ofthis invention can be prepared by introducing asphalt binder with adesired amount of polymer (e.g., unsaturated polymer) at a desiredtemperature. In one embodiment, the polymer may be added to moltenasphalt binder at temperatures greater than about 120° C., or in otherembodiments from about 140° C. to about 210° C. In one or moreembodiments, the polymer and asphalt may be mixed or blended after orduring introduction of the same. Mixing may then be continued for about25 to about 400 minutes at a temperature of about 145° C. to about 205°C. (or in other embodiments from about 160° C. to about 193° C.). In oneor more embodiments, the mixture of the asphalt binder and polymer maybe sheared in order to disperse the polymer quickly into the asphalt.Shearing may be accomplished, for example, within a high shear mill suchas that produced by Siefer. In other embodiments, simple low shearmixing may be employed where time is less important.

The modified asphalt binder compositions prepared according to thepresent invention may be employed to prepare asphalt pavingcompositions. These paving compositions may include the modified asphaltbinder, aggregate, and other optional constituents that can be addedinto paving compositions as is known in the art. Conventional aggregatethat is used in the paving industry can be utilized in the practice ofthis embodiment. Aggregate may include rocks, stones, slags, crushedstone, gravel, sand, silica, or mixtures of one more thereof. Specificexamples of aggregates include marble, limestone, basalt, dolomite,sandstone, granite, quartzite, steel slag, and mixture of two or morethereof.

Aggregate typically has a wide distribution of particle sizes rangingfrom sub-micron particles (e.g., dust) to golf-ball sized masses aslarge as 63 mm in diameter. The best particle size distribution variesfrom application to application.

In addition to the aggregate and the modified asphalt binder, the pavingcompositions of the present invention may also include otherconstituents or ingredients that may be used in preparing asphalt pavingcompositions. These additional constituents or ingredients may includefibers, release agents, and fillers. Other examples include calciumhydroxide, sanders dust, cellulose fibers, propylene-based fibers, andmixtures of two or more thereof.

The asphalt paving compositions of the present invention can be preparedby using standard equipment and procedures. In one or more embodiments,the aggregate is mixed with the modified asphalt binder to attain anessentially homogeneous asphalt paving. For instance, the aggregate canbe mixed with the modified asphalt binder to produce asphalt pavingcomposition on a continuous basis in a standard mixer.

When preparing an asphalt paving composition, generally from about 1weight percent to about 10 weight percent of the modified asphalt andfrom about 90 weight percent to about 99 weight percent aggregate (basedon the total weight of the asphalt paving composition) is mixed. Inother embodiments, the paving compositions include from about 2 to about8 weight percent of the modified asphalt.

The asphalt paving compositions prepared according to the presentinvention are particularly advantageous for preparing pavements. As isknown in the art, the pavement can be prepared by depositing the asphaltpaving composing onto a surface. These pavements may include, but arenot limited to, roadways, airport runways, walkways, trails, golf cartpaths, pond liner, landfill covers, and bridge decks. Also, the modifiedasphalt binder compositions of the present invention are advantageousfor making other compositions besides the pavement compositions. Forexample, the modified asphalt compositions may be useful in roofingapplications.

In order to demonstrate the practice of the present invention, thefollowing examples have been prepared and tested. The examples shouldnot, however, be viewed as limiting the scope of the invention. Theclaims will serve to define the invention.

EXAMPLES Samples 1-3 & Comparative 1-2

Two polymers in accordance with the present invention we prepared anddissolved in asphalt according to a standardized test procedure. Twocomparative polymers that were commercially obtained were likewisedissolved. The ease of dissolvability in the asphalt was recorded.

The characteristics of the polymers used are provided in Table Itogether with the results of the test. Comparative I was a radialpolymer, which refers to the fact that the polymer had at least 3 armsor branches, and each arm was believed to include a styrene-butadieneblock copolymer. Sample I was likewise a radial polymer and was preparedby coupling base polymer that was a styrene-butadiene block copolymerincluding diene end cap. Comparative I was determined to include about30% bound styrene, and Sample I was synthesized to include about thesame amount of bound styrene.

Comparative II was a linear polymer that was believed to include astyrene-butadiene-styrene block copolymer. Sample II was likewise alinear polymer that was prepared by di-coupling base polymer that was astyrene-butadiene block copolymer including diene end cap. Comparative Iwas determined to include about 30% bound styrene, and Sample I wassynthesized to include about the same amount of bound styrene.

TABLE I Examples Comparative 1 Sample 1 Comparative 2 Sample 2 Sample 3Structure Type Radial Radial Linear Linear Linear Mp Base (kg/mole) 7575 50 62 67   Mp cpld (kg/mole) 228 264 93 112 — Coupled (%) 89.0 77.025.0 27.0 27.0 vinyl (%) 16.5 24.0 13.4 24.0 24.0 30-Minute Melt Test 054 7 14.5 69.2

Each polymer, which was in pellet or crumb form, was tested according tothe following procedure. To a quart can container was added 500 grams ofasphalt binder preheated to 163° C. The asphalt binder was obtained fromBP (Whiting, Ind.) and had a PG rating of 64-22 per AASHTO M320. Using aquart can heater, the asphalt binder was heated to 190° C. The asphaltbinder was stirred by using a three-paddle agitator positioned aboutone-half inch above the bottom of the can and operating at sufficientr.p.m. to create a vortex in the asphalt. A portion of each polymer waspassed through a #4 (0.187 inch) sieve screen and a 20 gram sample wascollected. The screened polymer was slowly added to the stirred asphaltsample at a rate of about 20 gram per minute. Stirring continued for 30minutes at 190° C., during which time a scraping tool was employed tobreak up clumps of polymer.

After 30 minutes of mixing, the mixture of asphalt binder and polymerare passed through a pre-weighed 20-mesh sieve screen. The screen (withresidue of the mixture) is placed onto another quart can and placed intoan oven at 163° C. for one hour. After cooling for 15 minutes, thescreen and residue of the mixture are weighed. For purposes of thisanalysis, the weight of the residue remaining on the screen is assumedto be undissolved polymer, which is reported in Table I as a percentageof the original 20 gram sample as the 30-minute melt test.

The Mp of the sample was determined using GPC analysis with polystyrenestandards. As noted within this specification, the Mp represent the peakaverage molecular weight. As is known in the art, a multi-modal polymeror one that is partially coupled, it should be understood that each peakmay have its own Mp. The degree of coupling was determined from the areaof the peak in question as a function of the overall area under thecurve using standard GPC analysis. The vinyl content of the polymer wasdetermined by IR analysis.

As can be determined from the results of the tests, the polymersincluding diene end caps dissolved in the asphalt to a markedly greaterextent than the Comparative polymer, which did not include the diene endcap. Those skilled in the art appreciate that the particle size of thepolymer could impact the rate at which the polymer dissolves in theasphalt. While the polymer was screened to establish a maximum particlesize, variability within the particle sizes of the polymer could impactthe results of this test. But, visual inspection of the polymerparticles indicated that there was not a great degree of difference inparticle size, and therefore it was concluded that the difference inrate of dissolvability was attributable to the diene end cap.

Samples 4-9

Using anionic polymerization techniques, block styrene-butadiene polymerwith a diene end cap was prepared and di-coupled to form a linearpolymer (Samples 4-6) or coupled for form radial polymer (Samples 7-9).The characteristics of the polymers prepared are provided in Table II.The polymer samples were likewise analyzed using the 30-minute melt testdescribed above, and the results thereof are provided in Table II.

TABLE II Examples 4 5 6 7 8 9 Structure Type Linear Linear Linear RadialRadial Radial (Radial/Linear) Base Weight Ratio Diene End Cap 0.26 0.581.9 0.25 0.8 1.9 Vinyl Block 1 1 1 1 1 1 Diene Block 4.2 3.9 2.6 4.3 3.72.6 Mp (kg/mole) Base 66 68 70 71 66 75 Coupled 123 127 131 250 223 25530-Minute melt 16.2 25.6 37.0 38.7 48.4 83.2 test (%)

As can be determined from the results of the tests, the size of thediene end cap is directly proportional to the rate at which the polymer(both linear and radial) dissolve in the asphalt. Accordingly, it wasunexpectedly discovered that a technologically useful balance ofproperties could be achieved by varying the length of the diene end cap.

Various modifications and alterations that do not depart from the scopeand spirit of this invention will become apparent to those skilled inthe art. This invention is not to be duly limited to the illustrativeembodiments set forth herein.

1. (canceled)
 2. The process of claim 39, where each d includes from about 10 to about 500 mer units deriving from the polymerization of conjugate diene monomer.
 3. (canceled)
 4. The process of claim 39, where each D includes from about 400 to about 1,200 mer units deriving from the polymerization of conjugated diene monomer.
 5. (canceled)
 6. The process of claim 39, where each V includes from about 100 to about 500 mer units deriving from the polymerization of vinyl aromatic monomer.
 7. (canceled)
 8. The process of claim 39 where d derives from the polymerization of 1,3-butadiene.
 9. The process of claim 39, where D derives from the polymerization of 1,3-butadiene.
 10. The process of claim 39, where V derives from the polymerization of styrene.
 11. (canceled)
 12. (canceled)
 13. (canceled)
 14. (canceled)
 15. The process of claim 39, where the copolymer is star coupled by employing a tri-ester.
 16. The process of claim 15, where the tri-ester is trioctyl trimellitate.
 17. The process of claim 39, where the copolymer is star-coupled by employing a di-ester.
 18. The process of claim 17, where the di-ester is dioctyl terephthalate.
 19. (canceled)
 20. (canceled)
 21. The process of claim 39, where a derives from the concurrent oligomerization of divinylbenzene with living polymer chains.
 22. (canceled)
 23. (canceled)
 24. (canceled)
 25. (canceled)
 26. (canceled)
 27. (canceled)
 28. (canceled)
 29. (canceled)
 30. (canceled)
 31. (canceled)
 32. (canceled)
 33. (canceled)
 34. The composition of claim 41, where the mixture exhibits a melt index (ASTM D-1238, 2.16 kg @ 190° C.) of less than 2 dg/min.
 35. (canceled)
 36. (canceled)
 37. (canceled)
 38. (canceled)
 39. A process for preparing a modified asphalt composition, the process comprising: introducing a molten asphalt composition; introducing from about 0.1 to about 10 parts by weight, per 100 parts by weight of the modified asphalt composition, of a polymeric blend including a star-branched diene end-capped block copolymer and a linear diene end-capped block copolymer into the molten asphalt composition, where the star-branched block copolymer is defined by the formula α-(D-V-d)_(x) where each D is independently a polydiene block, each V is independently a vinyl aromatic block, each d is a polydiene end cap, α is a coupling moiety that couples at least three chains of a living polymer defined by formula d-V-D^(⊖), and x is an integer from 2 to 10, and where the linear block copolymer is defined by the formula (D-V-d) where each D is independently a polydiene block, each V is independently a vinyl aromatic block, each d is a polydiene end cap.
 40. A pavement prepared by: depositing onto a surface an asphalt paving composition prepared with a modified-asphalt composition prepared by introducing a molten asphalt composition; introducing from about 0.1 to about 10 parts by weight, per 100 parts by weight of the modified asphalt composition, of a polymeric blend including a star-branched diene end-capped block copolymer and a linear diene end-capped block copolymer into the molten asphalt composition, where the star-branched block copolymer is defined by the formula α-(D-V-d)_(x) where each D is independently a polydiene block, each V is independently a vinyl aromatic block, each d is a polydiene end cap, α is a coupling moiety that couples at least three chains of a living polymer defined by formula d-V-D^(⊖), and x is an integer from 2 to 10, and where the linear block copolymer is defined by the formula (D-V-d) where each D is independently a polydiene block, each V is independently a vinyl aromatic block, each d is a polydiene end cap.
 41. A composition prepared by the process of claim
 43. 42. The process of claim 39, wherein the step of introducing the polymeric blend includes introducing the blend having a molar ratio of star-branched block copolymer to linear block copolymer of at least 0.5:1 and less than 9.5:1.
 43. The process of claim 39, further comprising the step of introducing to the molten asphalt from about 0.1 parts to about 10 parts by weight curative, per 100 parts by weight asphalt.
 44. The pavement of claim 40, wherein the modified-asphalt composition is further prepared by introducing to the molten asphalt from about 0.1 parts to about 10 parts by weight curative, per 100 parts by weight asphalt. 